A high-life light battery swap connector

Abstract

The utility model discloses a long -life light -duty battery swap connector. The battery swap connector includes: the plug and the socket of coupling insertion, the plug includes the plug plastic shell and the multiple power terminals of integrative injection connection in the plug plastic shell, and the power terminal includes the cap and the needle body of surface silver plating, and the needle body inside hollow forms single -end open core chamber, and the mounting groove fixed connection cap of core chamber port, the socket includes the jack plastic shell and the multiple power jacks of integrative injection connection in the jack plastic shell, and the power jack includes the jack body and the batch groove spring piece of sleeve joint in the one end of jack body, the support cover, and the weight reduction hole is formed to the jack body end face center and is hollowed out, and the batch groove spring piece is located in the support cover and is elastically resisted to the inner wall of support cover through the spring wire, and the batch groove spring piece and the surface silver plating of jack body. The utility model has the effect that the weight is light, the endurance ability is high and the service life is high.

Description

Technical Field

[0001] This utility model relates to the field of battery swapping connectors, and in particular to a high-life, lightweight battery swapping connector. Background Technology

[0002] Industrial drones are widely used in industry and agriculture. Because drones are required to be lightweight, most have short flight times. Battery-swapping drones use battery-swapping connectors for quick battery replacement, solving problems such as long charging times and short flight times. However, their drawbacks are: First, current battery-swapping connectors are heavy, affecting flight time and requiring frequent battery replacements. Second, the use of gold-plated pins increases the overall cost due to rising gold prices, and the high contact resistance of gold-plated pins also results in poor current carrying capacity and higher temperature rise, leading to burn-out of the spring contacts and reducing connector lifespan. Third, current socket structures use replaceable spring contacts, which have short lifespans. As the pins constantly wear down the spring contacts, they need to be replaced periodically, causing inconvenience and increasing operating costs. Utility Model Content

[0003] To address one or more of the aforementioned problems, this utility model provides a high-life, lightweight battery swapping connector.

[0004] According to one aspect of the present invention, a high-life, lightweight battery swapping connector includes: The plug includes a plug housing and multiple power terminals integrally injection molded and connected within the plug housing. The power terminals include caps and silver-plated pins. The pins are hollow inside to form a single-ended open core cavity, and the caps are fixedly connected to the mounting slots at the core cavity ports. The socket includes a socket housing and multiple power sockets integrally injection molded within the socket housing. Each power socket includes a socket body, a slotting spring, and a support sleeve fitted onto one end of the socket body. The center of the socket body end face is hollowed out to form a weight-reducing hole. The slotting spring is located inside the support sleeve and elastically abuts against the inner wall of the support sleeve via a spring wire. The surfaces of the slotting spring and the socket body are silver-plated.

[0005] In some embodiments, the mounting groove of the needle body is coaxially arranged at the core cavity port, and an annular groove is also provided in the mounting groove; the cap includes a cylindrical cap body and a plurality of spring teeth arranged in an integral circumferential array at the rear end of the cap body, the cap body is inserted into the mounting groove with interference fit and the spring teeth are elastically inserted into the groove.

[0006] In some embodiments, an annular protrusion is integrally provided in the middle of the core cavity, with a slot on the inner side and a mounting groove on the outer side; the positioning groove in the middle of the spring tooth accommodates the protrusion; and the end of the spring tooth is also provided with a chamfered buffer surface.

[0007] In some embodiments, the needle body is precision machined after cold heading; The needle body, groove spring, and socket body are electroplated with Ni2Ag3 silver material.

[0008] In some embodiments, the front end of the slotted spring is provided with a connecting ring, the rear end of the socket body is provided with an inner fixing shaft, the inner fixing shaft is sleeved with the connecting ring of equal diameter, the slotted spring and the socket body are welded together, and then both surfaces are silver plated.

[0009] In some embodiments, the slotted spring also includes several circumferentially arrayed pieces integrally connected to the rear end of the connecting ring, with an axial gap between adjacent pieces, and a front groove at the front end of each piece, the several front grooves forming an annular fixing groove, with the spring wire interference-fitted into the fixing groove.

[0010] In some embodiments, the front end of the support sleeve is fitted with the outer fixed shaft of the insertion hole body with a constant diameter; The outer wall of the outer fixed shaft is provided with multiple glue grooves in a circular array, and the outer wall of the front end of the support sleeve is provided with multiple glue passage holes in a circular array. The rear end of the sheet body is connected to the U-shaped inner flange of the support sleeve, and each glue passage hole is directly opposite a glue groove.

[0011] In some embodiments, vertical stepped holes are provided on both sides of the insert housing, and the guide sleeve is integrally injection molded to the front injection hole of the stepped hole, with its shaft hole and the rear guide sliding hole of the stepped hole being flush and aligned; the positioning grooves at both ends of the guide sliding hole are integrally injection molded to the two end rings of the guide sleeve.

[0012] In some embodiments, the inner wall of the end ring is further provided with a first guide fillet; the head of the guide post is bullet-shaped, and the head is provided with a first fillet and a chamfered ramp located at the outer end of the first fillet.

[0013] In some implementations, the lightweight battery swapping connector is used in any of the following: drones, charging and swapping agricultural machinery, charging and swapping robots, and simple battery swapping vehicles.

[0014] The advantages of this high-lifespan lightweight battery swapping connector are as follows: First, by using a plug with lightweight terminals and a socket with lightweight insertion holes—namely, hollow power terminals and hollowed-out power insertion holes—combined with an injection-molded shell, the main components of the plug and socket are reduced in material, resulting in lighter connector weight, improved battery life, reduced battery replacement frequency, and increased efficiency. Second, the power terminals are silver-plated, and the power insertion holes are also silver-plated. The silver plating process offers a longer lifespan and excellent properties such as low contact resistance, low insertion and extraction force, good lubrication, and low coefficient of friction. This improves the overall current carrying capacity and reduces overall temperature rise, significantly reducing the burning phenomenon after spring wear and extending the connector's lifespan. Furthermore, silver is cheaper than gold, effectively reducing the overall cost of the connector. Third, the power insertion holes are silver-plated with a grooved structure. When frequent mating wear occurs, the spring wire allows the grooved spring to elastically deform and tightly grip the terminals, eliminating the need for replacement and in-use wear monitoring. This makes it convenient to use and effectively reduces costs. The superior performance of silver plating also significantly extends the connector's lifespan. Attached Figure Description

[0015] Figure 1 This is a three-dimensional schematic diagram of a high-life lightweight battery swapping connector according to one embodiment of the present invention. Figure 2 for Figure 1 A three-dimensional schematic diagram of the plug shown; Figure 3 for Figure 2 A three-dimensional exploded view of the power terminals shown. Figure 4 for Figure 1 A three-dimensional schematic diagram of the socket shown; Figure 5 for Figure 4 A three-dimensional schematic diagram of the power jack shown; Figure 6 for Figure 4 A three-dimensional exploded view of the power jack shown; Figure 7 for Figure 4 A cross-sectional view of the guide sleeve shown; Plug 01, plug housing 1, power terminal 2, pin body 20, core cavity 200, mounting groove 201, protruding ridge 202, card slot 203, cap 21, cap body 210, spring tooth 211, positioning groove 212, chamfered buffer surface 213, guide post 5, head 51, first rounded corner 52, chamfered ramp 53, low-voltage pin 8; Socket 02, socket housing 3, injection hole 31, guide hole 32, positioning groove 33, power socket 4, socket body 40, weight reduction hole 400, inner fixed shaft 401, outer fixed shaft 402, first positioning surface 403, second positioning surface 404, glue groove 405, slotted spring piece 41, piece body 410, front groove 411, connecting ring 412, support sleeve 42, glue passage hole 421, inner flange 422, arc surface 423, chamfered surface 424, spring wire 43; guide sleeve 6, end ring 61, first guide radius 62, low-voltage socket 7. Detailed Implementation

[0016] The present invention will now be described in further detail with reference to the accompanying drawings. It should be noted that the terms "front," "rear," "left," "right," "up," and "down" used in the following description refer to the directions in the accompanying drawings, while the terms "inner" and "outer" refer to the directions toward or away from the geometric center of a specific component, respectively.

[0017] Figures 1 to 7 A high-life, lightweight battery swapping connector according to one embodiment of the present invention is schematically shown. As shown, the high-life, lightweight battery swapping connector includes: The plug 01 includes a plug housing 1 and multiple power terminals 2 integrally injection-molded within the plug housing 1. Each power terminal 2 includes a cap 21 and a silver-plated needle body 20. The needle body 20 is hollow, forming a single-ended open core cavity 200. A mounting groove 201 at the port of the core cavity 200 is fixedly connected to the cap 21, forming a lightweight terminal. Furthermore, the mounting groove 201 of the needle body 20 is coaxially positioned at the port of the core cavity 200, and an annular retaining groove 203 is also provided within the mounting groove 201, facilitating assembly. The cap 21 includes a cylindrical cap body 210 and several spring teeth 211 integrally arranged in a circumferential array at the rear end of the cap body 210. The cap body 210 is press-fitted into the mounting groove 201, and the spring teeth 211 elastically press-fit into the retaining groove 203. This configuration effectively seals the core cavity 200, preventing liquid and moisture from entering. Preferably, the needle body 20 is precision machined after cold heading.

[0018] Socket 02 includes a socket housing 3 and multiple power sockets 4 integrally injection molded and connected within the socket housing 3. Each power socket 4 includes a socket body 40 and a slotting spring 41 and a support sleeve 42 sleeved on one end of the socket body 40. The center of the end face of the socket body 40 is hollowed out to form a weight reduction hole 400. The slotting spring 41 is located inside the support sleeve 42 and it elastically abuts against the inner wall of the support sleeve 42 through a spring wire 43. The surfaces of the slotting spring 41 and the socket body 40 are silver plated to form a high-life lightweight socket. Furthermore, the socket body 40 and the slotted spring 41 are preferably made of copper. The socket body 40 is machined from a copper column, and the slotted spring 41 is punched and rolled from a copper tube. This choice has high conductivity and high production efficiency with low cost. The spring wire 43 is preferably made of stainless steel wire. Stainless steel has high strength and high rigidity and is suitable for high-temperature environments. The support sleeve 42 is made of stainless steel tube or stainless steel ring stretched. This design avoids the generation of gaps and can achieve good injection molding and sealing.

[0019] The plug 01 is inserted into the socket 02, and the pin 20 is perpendicular to the slotted spring 41 and is elastically held by the slotted spring 41. The silver plating material on the surfaces of the pin 20, the slotted spring 41, and the socket body 40 is preferably Ni2Ag3.

[0020] The advantages of this high-lifespan lightweight battery swapping connector are as follows: First, the connector uses a plug 01 with lightweight terminals and a socket 02 with lightweight insertion holes, namely, hollow power terminals 2 and hollowed-out power insertion holes 4. Combined with an injection-molded shell, the materials of the main components of the plug 01 and socket 02 are reduced, resulting in weight reduction. This improves battery life, decreases battery replacement frequency, and increases efficiency. Second, the power terminals 2 and 4 are silver-plated. The silver plating process offers a longer lifespan and features low contact resistance, low insertion / extraction force, good lubrication, and a low coefficient of friction. The superior performance of the silver plating process improves the overall current carrying capacity and reduces the overall temperature rise, greatly reducing the burning phenomenon after the spring wears off and extending the service life of the connector. At the same time, the unit price of silver metal is relatively cheaper than that of gold, effectively reducing the overall cost of the connector. Thirdly, the power socket 4 adopts a silver-plated socket with a groove structure. When frequent mating wear occurs, the spring wire 43 can make the groove spring 41 elastically deform and tightly hold the terminal, so that there is no need to replace it or monitor the wear during use. It is convenient to use and effectively reduces costs. At the same time, the excellent performance of low contact resistance, low insertion and extraction force, lubrication, and low coefficient of friction brought by the silver plating process greatly improves the service life of the connector.

[0021] Furthermore, the core cavity 200 is integrally provided with an annular protrusion 202 in the middle, with a slot 203 on the inner side and a mounting groove 201 on the outer side; The positioning groove 212 in the middle of the spring tooth 211 accommodates the protruding ridge 202, and an axial cut is provided between adjacent spring teeth 211; the end of the spring tooth 211 is also provided with a chamfered buffer surface 213. Its beneficial effects are: this setting further improves the tightness of the connection, prevents foreign objects from entering, and achieves long-term safe conduction.

[0022] Furthermore, the front end of the slotted spring 41 is provided with a connecting ring 412, and the rear end of the insertion body 40 is provided with an inner fixed shaft 401. The inner fixed shaft 401 is sleeved with the connecting ring 412 at the same diameter. The connection between the slotted spring 41 and the insertion body 40 is welded, and then both surfaces are silver-plated. Preferably, the rear end of the insertion body 40 is also provided with an outer fixed shaft 402. The outer fixed shaft 402 is coaxially located at the front end of the inner fixed shaft 401 and its diameter is larger than that of the inner fixed shaft 401. The two form a stepped shaft, and the front end of the support sleeve 42 is sleeved with the outer fixed shaft 402 at the same diameter. The insertion body 40 is also provided with a first positioning surface 403. The connection between the outer fixed shaft 402 and the inner fixed shaft 401 forms a second positioning surface 404. The end face of the connecting ring 412 fits against the second positioning surface 404, and the end face of the support sleeve 42 fits against the first positioning surface 403. The beneficial effect is that the slotted spring 41 has good installation accuracy and is easy to process and manufacture.

[0023] Preferably, the slotted spring 41 further includes several circumferentially arrayed sheet bodies 410 integrally connected to the rear end of the connecting ring 412. An axial gap exists between adjacent sheet bodies 410. Each sheet body 410 has a front groove 411 at its front end, and the several front grooves 411 form an annular fixing groove. The spring wire 43 is interference-fitted into the fixing groove. The beneficial effect is that this arrangement prevents the spring wire 43 from shaking, thereby ensuring the stable position of the spring wire 43 and achieving stable conduction.

[0024] Furthermore, the outer wall of the outer fixed shaft 402 of the socket body 40 is provided with a plurality of glue grooves 405 arranged in a circular array, and the outer wall of the front end of the support sleeve 42 is provided with a plurality of glue-through holes 421 arranged in a circular array, and the rear end is bent into a U-shaped inner flange 422. After the two are sleeved together, the rear end of the sheet body 410 is inserted into the U-shaped inner flange 422, and each glue-through hole 421 is directly opposite a glue groove 405. The tube hole of the socket shell 3 is integrally injection molded to cover the support sleeve 42 and the outer peripheral wall of the socket body 40, and the radial connecting feet of the socket shell 3 are integrally injection molded to connect the glue-through holes 421 and the glue grooves 405; the glue groove 405 is preferably an arc-shaped elongated groove, and the glue-through hole 421 is preferably an annular rectangular hole. Its beneficial effect is that this setting can achieve good connection strength of the power socket 4.

[0025] The front end of the socket body 40 is also provided with a small-diameter end connector and a reinforcing groove located at the end connector. The socket plastic shell 3 is integrally injection molded to cover the end connector and the reinforcing groove, and the outer end of the socket body 40 protrudes from the outer wall of the socket plastic shell 3.

[0026] The inner flange 422 port of the support sleeve 42 preferably has an inclined chamfered surface 424 and an arc surface 423. The beneficial effects are: this setting facilitates insertion and removal, reduces wear, and improves service life.

[0027] Furthermore, the plug housing 1 is integrally injection molded to connect four rectangular arrays of power terminals 2, two integrally injection molded symmetrically connected guide posts 5 on both sides, and multiple rectangular arrays of low-voltage pins 8 integrally injection molded at the center; The socket housing 3 is integrally injection molded to connect four rectangular arrays of power sockets 4; two guide sleeves are integrally injection molded symmetrically on both sides 6; and multiple rectangular arrays of low-voltage sockets 7 are integrally injection molded at the center 7. When plug 01 is coupled to socket 02, guide post 5 is inserted into guide sleeve 6, power terminal 2 is inserted into power socket 4, and low-voltage pin 8 is inserted into low-voltage socket 7. Its beneficial effect is that this setup achieves a single-sided dual-branch, left-right one-in-one-out structure, meeting high current requirements of 450A and above.

[0028] Furthermore, the plastic shell 3 of the insertion hole is provided with vertical stepped holes on both sides. The outer stepped hole of the vertical stepped hole is a large-diameter injection hole 31 and the inner stepped hole is a small-diameter guide hole 32. The guide sleeve 6 is integrally injection molded and connected to the injection hole 31, and its shaft hole and the guide hole 32 are aligned front and back. The guide hole 32 is provided with annular positioning grooves 33 at both ends. Its beneficial effect is that this setting further optimizes the component weight of the guide sleeve 6 and further reduces its weight.

[0029] The guide sleeve 6 includes a circular tube body with two end rings 61 integrally protruding outward radially at both ends; the end rings 61 are integrally injection molded to connect to the positioning groove 33. Its advantages are: this design achieves good installation, fixation, and guiding performance.

[0030] Preferably, the inner wall of the end ring 61 is also provided with a first guide fillet 62. The head 51 of the guide post 5 has a bullet-shaped structure, with a first fillet 52 at the front end of the head 51 and a chamfered ramp 53 located at the outer end of the first fillet 52, thereby forming a bullet-shaped structure to facilitate better guiding transition. Its beneficial effects are: this setting avoids the accumulation of dust, fine abrasive particles and other impurities on the guide post 5, prevents jamming and reduces wear, and improves the service life of the guide structure.

[0031] Among them, the guide sleeve 5 is made by cutting the steel pipe, bending and flanging both ends, and then processing the rounded corners, which facilitates the guiding transition. Finally, it is integrally injection molded into the plastic shell. Its beneficial effects are: this setting facilitates processing and manufacturing, and can reduce product costs.

[0032] Furthermore, this lightweight battery swapping connector can be applied to any of the following: drones, charging and swapping agricultural machinery, charging and swapping robots, and simple battery swapping vehicles; When used in drones, plug 01 is fixed to the drone end and socket 02 is fixed to the battery pack end. Its advantage is that this connector has a wide range of applications.

[0033] The above descriptions are merely some embodiments of this utility model. For those skilled in the art, various modifications and improvements can be made without departing from the inventive concept of this utility model, and all such modifications and improvements fall within the protection scope of this utility model.

Claims

1. A high-life, lightweight battery swapping connector, characterized in that, include: The plug (01) includes a plug housing (1) and multiple power terminals (2) integrally injection molded and connected in the plug housing (1). The power terminals (2) include a cap (21) and a silver-plated needle body (20). The needle body (20) is hollow inside to form a single-end open core cavity (200). The mounting groove (201) at the port of the core cavity (200) is fixedly connected to the cap (21). The socket (02) includes a socket shell (3) and multiple power sockets (4) integrally injection molded and connected in the socket shell (3). The power sockets (4) include a socket body (40) and a grooving spring (41) and a support sleeve (42) sleeved on one end of the socket body (40). The center of the end face of the socket body (40) is hollowed out to form a weight reduction hole (400). The grooving spring (41) is located in the support sleeve (42) and it elastically abuts against the inner wall of the support sleeve (42) through a spring wire (43). The surfaces of the grooving spring (41) and the socket body (40) are silver plated.

2. The battery swapping connector according to claim 1, characterized in that, The mounting groove (201) of the needle body (20) is coaxially arranged at the port of the core cavity (200), and the mounting groove (201) is also provided with an annular groove (203); the cap (21) includes a cylindrical cap body (210) and a number of spring teeth (211) arranged in an integral circumferential array at the rear end of the cap body (210), the cap body (210) is inserted into the mounting groove (201) and the spring teeth (211) are elastically inserted into the groove (203).

3. The battery swapping connector according to claim 2, characterized in that, The core cavity (200) is integrally provided with an annular protrusion (202) in the middle, the inner side of the annular protrusion (202) is a slot (203) and the outer side is a mounting slot (201); the positioning groove (212) in the middle of the spring tooth (211) accommodates the protrusion (202); the end of the spring tooth (211) is also provided with a chamfered buffer surface (213).

4. The battery swapping connector according to any one of claims 1 to 3, characterized in that, The needle body (20) is precision machined after cold heading; The needle body (20), the groove spring (41), and the socket body (40) are electroplated with silver material Ni2Ag3.

5. The battery swapping connector according to claim 1, characterized in that, The front end of the slotted spring (41) is provided with a connecting ring (412), and the rear end of the socket body (40) is provided with an inner fixing shaft (401). The inner fixing shaft (401) is sleeved with the connecting ring (412) of equal diameter. The slotted spring (41) and the socket body (40) are welded together, and then both surfaces are silver plated.

6. The battery swapping connector according to claim 5, characterized in that, The slotted spring sheet (41) also includes several circumferential array of sheet bodies (410) integrally connected to the rear end of the connecting ring (412). There is an axial gap between adjacent sheet bodies (410). Each sheet body (410) has a front groove (411) at its front end. Several front grooves (411) form an annular fixing groove. The spring wire (43) is interference-fitted into the fixing groove.

7. The battery swapping connector according to claim 6, characterized in that, The support sleeve (42) is connected to the outer fixed shaft (402) of the equal diameter sleeve insertion hole body (40) at the front end of the support sleeve (42). The outer wall of the outer fixed shaft (402) is provided with a plurality of glue grooves (405) arranged in a circular array, and the outer wall of the front end of the support sleeve (42) is provided with a plurality of glue passage holes (421) arranged in a circular array. The rear end of the sheet (410) is inserted into the U-shaped inner flange (422) of the support sleeve (42), and each glue passage hole (421) is directly opposite a glue groove (405).

8. The battery swapping connector according to claim 1, characterized in that, The plug shell (3) has vertical stepped holes on both sides. The guide sleeve (6) is integrally injection molded to the front injection hole (31) of the stepped hole, and its shaft hole and the rear guide sliding hole (32) of the stepped hole are flush and aligned. The positioning grooves (33) at the front and rear ends of the guide sliding hole (32) are integrally injection molded to the two end rings (61) of the guide sleeve (6).

9. The battery swapping connector according to claim 8, characterized in that, The inner wall of the end ring (61) is also provided with a first guide fillet (62); the head (51) of the guide post (5) is bullet-shaped, and the head (51) is provided with a first fillet (52) and a chamfered ramp (53) located at the outer end of the first fillet (52).

10. The battery swapping connector according to claim 1, characterized in that, This lightweight battery swapping connector can be used in any of the following: drones, agricultural machinery requiring charging and swapping, charging and swapping robots, and simple battery swapping vehicles.

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